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US20050197413A1 - Flexible molded parts of expanded polyurethane and their use - Google Patents

Flexible molded parts of expanded polyurethane and their use Download PDF

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Publication number
US20050197413A1
US20050197413A1 US11/069,241 US6924105A US2005197413A1 US 20050197413 A1 US20050197413 A1 US 20050197413A1 US 6924105 A US6924105 A US 6924105A US 2005197413 A1 US2005197413 A1 US 2005197413A1
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Prior art keywords
polyols
mole
polyether
polyol
component
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US11/069,241
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Inventor
Wolfgang Grimm
Erhard Michels
Klaus Brecht
Uwe Pfeuffer
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Covestro Deutschland AG
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Individual
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Assigned to BAYER MATERIALSCIENCE AG reassignment BAYER MATERIALSCIENCE AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MICHELS, ERHARD, GRIMM, WOLFGANG, PFEUFFER, UWE, BRECHT, KLAUS
Publication of US20050197413A1 publication Critical patent/US20050197413A1/en
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/32—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof from compositions containing microballoons, e.g. syntactic foams
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/4009—Two or more macromolecular compounds not provided for in one single group of groups C08G18/42 - C08G18/64
    • C08G18/4018—Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/42—Polycondensates having carboxylic or carbonic ester groups in the main chain
    • C08G18/4244—Polycondensates having carboxylic or carbonic ester groups in the main chain containing oxygen in the form of ether groups
    • C08G18/4247—Polycondensates having carboxylic or carbonic ester groups in the main chain containing oxygen in the form of ether groups derived from polyols containing at least one ether group and polycarboxylic acids
    • C08G18/4252—Polycondensates having carboxylic or carbonic ester groups in the main chain containing oxygen in the form of ether groups derived from polyols containing at least one ether group and polycarboxylic acids derived from polyols containing polyether groups and polycarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4804—Two or more polyethers of different physical or chemical nature
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0008—Foam properties flexible
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0033—Foam properties having integral skins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0041—Foam properties having specified density
    • C08G2110/0066—≥ 150kg/m3
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/22—Expandable microspheres, e.g. Expancel®
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • C08J2375/04—Polyurethanes

Definitions

  • the present invention relates to flexible molded parts of expanded polyurethane in which the molded parts have average densities of ⁇ 350 kg/m 3 and which have an unilaterally compact skin on one side, and that exhibit good molded part stability (i.e. the molded part shrinkage is ⁇ 1.5%; according to DIN ISO 02769).
  • the present invention also relates to a process for the production of these flexible molded parts, and to their use, particularly in the shoe sector.
  • the object of the present invention was to provide a process suitable for the production of molded parts of low densities and high wear resistance.
  • the wear resistance is in this connection achieved by means of a thick skin that is unilaterally formed on the side of the molded part of integral structure exposed to wear.
  • the present invention relates to flexible molded parts of expanded polyurethane in which the molded parts have average densities of ⁇ 350 kg/m 3 , preferably ⁇ 300 kg/m 3 , and have an unilaterally compacted edge zone (skin) with a thickness of 0.5 mm to 3 mm, preferably 0.7 mm to 2.5 mm, which has an average density of >650 kg/m 3 , and enclosed hollow microspheres, with a molded part shrinkage of ⁇ 1.5% (according to DIN ISO 02769).
  • These flexible molded parts comprise the reaction product of:
  • the component used as d1) is added to the polyol component b) and/or to the polyisocyanate component a).
  • the blowing agent used as component d2) is preferably added to the polyol component b).
  • the blowing agent used as component d3) may either be metered in separately or added to the polyol component b).
  • the present invention also provides a process for the production of the flexible molded parts according to the invention from expanded polyurethane in which the molded parts have average densities of ⁇ 350 kg/m 3 , preferably ⁇ 300 kg/m 3 , and have an unilaterally compacted edge zone (skin) having a thickness of 0.5 to 3 mm, preferably 0.7 to 2.5 mm, in which the edge zone has an average density of >650 kg/m 3 and contains enclosed hollow microspheres.
  • These molded parts have a part shrinkage of ⁇ 1.5% (according to DIN ISO 02769).
  • Isocyanate Index denotes the molar ratio of the NCO groups of the polyisocyanate component that is used to the NCO-reactive terminal groups of the components b), c) and d), multiplied by 100.
  • An Isocyanate Index of 100 corresponds to a stoichiometric amount of isocyanate groups to NCO-reactive terminal groups.
  • OH number (or hydroxyl number) denotes the molecular weight of KOH multiplied by 1,000 and by the functionality of the polyol, divided by the molecular weight of the polyol.
  • Suitable polyisocyanates to be used as component a) for the molded parts according to the present invention are aliphatic, cycloaliphatic, araliphatic, aromatic and heterocyclic polyisocyanates, as are described by, for example, W. Siefken in Justus Liebigs Annalen der Chemie, 562, pages 75 to 136. These polyisocyanates include, for example, those which correspond to the formula: Q(NCO) n
  • Suitable polyisocyanates include, for example, ethylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate (HDI), 1,12-dodecane diisocyanate, cyclobutane-1,3-diisocyanate, cyclohexane-1,3 diisocyanate and cyclohexane-1,4 diisocyanate as well as arbitrary mixtures of these isomers, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane, 2,4-hexahydrotoluylene diisocyanate and 2,6-hexahydrotoluylene diisocyanate as well as arbitrary mixtures of these isomers, hexahydro-1,3-phenylene diisocyanate and hexahydro-1,4-phenylene diisocyanate, perhydro-2,4′-diphenylme
  • polyisocyanate include, for example, the following: triphenylmethane-4,4′,4′′-triisocyanate, polyphenylpolymethylene polyisocyanates as are obtained by aniline/formaldehyde condensation and subsequent phosgenation and as described in, for example, GB-PS 874 430 and GB-PS 848 671, the disclosures of which are hereby incorporated by reference, m-isocyanatophenylsulfonyl isocyanate and p-isocyanatophenylsulfonyl isocyanate as described in, for example, U.S. Pat. No.
  • polyisocyanates containing acylated urea groups as described in, for example, to DE-PS 1 230 778 the disclosure of which is hereby incorporated by reference, polyisocyanates containing biuret groups, as are described in, for example, U.S. Pat. Nos. 3,124,605, 3,201,372 and 3,124,605, the disclosures of are hereby incorporated by reference, as well as in GB-PS 889,050, polyisocyanates produced by telomerisation reactions, as are described in, for example, U.S. Pat. No.
  • distillation residues occurring in industrial isocyanate production and containing isocyanate groups optionally dissolved in one or more of the aforementioned polyisocyanates.
  • the industrially readily accessible polyisocyanates are preferably used such as, for example, 2,4-toluylene diisocyanate and 2,6-toluylene diisocyanate, as well as arbitrary mixtures of these isomers (“TDI”), 4,4′-diphenylmethane diisocyanate, 2,4′-diphenylmethane diisocyanate, 2,2′-diphenylmethane diisocyanate and polyphenyl/polymethylene polyisocyanates, such as are produced by aniline/formaldehyde condensation and subsequent phosgenation (“crude MDI”), and polyisocyanates containing carbodiimide groups, uretonimine groups, urethane groups, allophanate groups, isocyanurate groups, urea groups or biuret groups (“i.e.
  • modified polyisocyanates include those modified polyisocyanates that are derived from 2,4-toluylene diisocyanate and/or 2,6-toluylene diisocyanate, or from 4,4′-diphenylmethane diisocyanate and/or 2,4′-diphenylmethane diisocyanate. Naphthylene-1,5-diisocyanate and mixtures of the aforementioned polyisocyanates are also very suitable.
  • prepolymers containing isocyanate groups that are produced by reacting at least a partial amount of polyol component b1), b2.1), b2.2), or a mixture thereof, and/or chain extenders and/or crosslinking agents c), with at least one aromatic diisocyanate from the group TDI, MDI, TODI, DIBDI, NDI, DDI, and preferably with 4,4′-MDI and/or 2,4-TDI and/or 1,5-NDI to form a polyaddition product containing urethane groups and isocyanate groups which has an NCO group content of 6 to 35 wt. %, preferably 10 to 25 wt. %.
  • the prepolymers containing isocyanate groups may be produced in the presence of catalysts. It is, however, also possible to produce the prepolymers containing isocyanate groups in the absence of catalysts, and to incorporate the latter in the reaction mixture only for the production of the PUR elastomers.
  • non-reactive additives low molecular weight esters such as phthalates, adipates, but also ring esters, cyclic carbonates and terminally blocked polyethers may also be added to the prepolymer.
  • polyether ester polyol as used herein is understood to denote a compound that contains ether groups, ester groups and OH groups.
  • the polyol component b) comprises b1) one or more polyether ester polyols as described in detail below; b2) a mixture of b2.1) one or more polyester polyol components, and b2.2) one or more polyether polyol components as described below; b3) one or more polyether polyol components as described below; b4) one or more polyester polyol components as described below; b5) a mixture of b1) and b2); b6) a mixture of b1) and b3); and b7) a mixture of b1) and b4).
  • Suitable polyether ester polyols to be used as the polyether ester polyols b1) in accordance with the present invention have a number average molecular weight of 800 g/mole to 6,000 g/mole, preferably 1,200 g/mole to 4,000 g/mole, a number average hydroxyl functionality of 1.7 to 4, preferably 1.8 to 2.7, and a weight ratio of ether groups to ester groups of 5:95 to 48:52, and more preferably of 8:92 to 30:70.
  • Such polyether ester polyols are those comprising the polycondensation products of: b1.1) one or more dicarboxylic acids which contain up to 12 carbon atoms and/or their derivatives; b1.2) one or more polyether polyols components that are selected from the group consisting of (i) one or more polyether polyols with a number average molecular weight of 1,000 g/mole to 8,000 g/mole and an ethylene oxide content of 10 to 40 wt. %, and (ii) one or more ether based polymer polyols with OH numbers of 10 to 149 and mean functionalities of 1.7 to 4, and which contain 1 to 50 wt.
  • % solids based on the total weight of the polymer polyols; b1.3) one or more polyols with a number average molecular weight of 62 to 750 g/mole, a number average functionality of 2 to 8 and which contain at least two terminal OH groups per molecule; and, optionally, b1.4) one or more ester-based polymer polyols having OH numbers of 10 to 149 and average functionalities of 1.7 to 4, and which contain 1 to 50 wt. % of solids, based on the total weight of polymer polyol.
  • Suitable organic dicarboxylic acids to be used as component b1.1) for preparing the polyether ester polyol component include those dicarboxylic acids with up to 12 carbon atoms.
  • Preferred organic dicarboxylic acids are those aliphatic dicarboxylic acids with 4 to 6 carbon atoms, which may be used either individually or as a mixture.
  • Suberic acid, azelaic acid, decanedicarboxylic acid, maleic acid, malonic acid, phthalic acid, pimelic acid and sebacic acid are disclosed as suitable, but non-limiting examples. Fumaric acid and succinic acid are more preferred, and glutaric acid and adipic acid are most preferred.
  • Suitable derivatives of these acids include, by way of example, the corresponding anhydrides as well as the corresponding esters and half-esters with low molecular weight, monohydric alcohols with 1 to 4 carbon atoms.
  • Suitable compounds to be used as component b1.2) for the production of the polyether ester polyols b1) are the polyether polyols b1.2 (i) that are obtained by alkoxylation of suitable starter molecules, and preferably polyhydric alcohols. These suitable starter molecules are at least difunctional, but may optionally also contain proportions of higher functional, and in particular trifunctional, starter molecules.
  • the alkoxylation is normally carried out in two steps. First, an alkoxylation is carried out in the presence of basic catalysts or double metal cyanide catalysts, preferably with propylene oxide or, less preferably, with 1,2-butylene oxide or, even less preferably, with 2,3-butylene oxide, and this is followed by ethoxylation of the propoxylation product with ethylene oxide.
  • the proportion of ethylene oxide in the polyether polyol is 10 wt. % to 40 wt. %, preferably 15 wt. % to 35 wt. %, and more preferably 18 wt. % to 32 wt. %.
  • component b1.2 there may be used b1.2) (ii) the ether-based polymer polyols with OH numbers of 10 to 149 and mean functionalities of 1.7 to 4. These polymer polyols typically contain 1 to 50 wt. % of solids, referred to the total weight of polymer polyol.
  • Suitable compounds to be used as component b1.3) for preparing the polyether ester polyols b1) of the invention are those polyols having a number average functionality of 2 to 8, and preferably diols, and which preferably contain at least two primary OH groups, and which have number average molecular weights of 62 g/mole to 750 g/mole, preferably 62 g/mole to 400 g/mole, more preferably 62 g/mole to 200 g/mole.
  • polyols which have number average functionalities above 2 and up to 8, preferably 2.1 to 5, and more preferably 3 to 4.
  • polyols include compounds such as, for example 1,1,1-trimethylolpropane, triethanolamine, glycerol, sorbitan and pentaerythritol, as well as polyethylene oxide polyols started on triols and/or tetraols which have mean molecular weights of 62 g/mole to 750 g/mole, preferably 62 g/mole to 400 g/mole, and more preferably 62 g/mole to 200 g/mole.
  • each member of the group of diols may be used either individually or in combination with other diols and/or polyols.
  • the diols and polyols, i.e. component b1.3) may also be added subsequently to a polyester polyol, even if they are not thereby converted or at least not until the polycondensation equilibrium is reached in the esterification reaction.
  • the relative quantitative use of polyols is restricted by the predetermined number average hydroxyl functionality of the polyether ester polyol, component b1).
  • Suitable compounds to be used as polymer polyols for component b1.4)(ii), component b2.1)(ii) and component b4)(ii) are polymer-modified polyols, and particularly graft polymer polyols based on polyesters or polyether esters.
  • Suitable for use as the graft component are, in particular, those graft components based on styrene and/or acrylonitrile, which are produced by in situ polymerization of acrylonitrile, styrene, or preferably mixtures of styrene and acrylonitrile.
  • Preferred mixtures of styrene and acrylonitrile include those, for example, with styrene and acrylonitrile in a weight ratio of 90:10 to 10:90, and more preferably 70:30 to 30:70.
  • the polymer polyols may be present as polyol dispersions, which contain as dispersed phase, for example, polyureas (PHD), polyhydrazides, and polyurethanes containing bound tert.-amino groups. Typically, these contain amounts of 1 to 50 wt. %, preferably 1 to 45 wt. % of solids, based on the total weight of the polymer polyol.
  • the mixture b2) consists of b2.1) and b2.2).
  • Component b2.1) comprises one or more polyester polyol components selected from the group consisting of (i) one or more polyester polyols with a number average molecular weight of 1,000 to 4,000 g/mole and a functionality of 1.7 to 4, and (ii) one or more ester-based polymer polyols with an OH number of 10 to 149 and mean functionalities of 1.7 to 4, preferably 1.8 to 3.5 and which contain 1 to 50 wt. % of solids, based on the total weight of the polymer polyol.
  • Suitable ester-based polymer polyols for component b2.1)(ii) are as described above.
  • Suitable polyester polyols for component b2.1)(i) and component b4)(i) include compounds which, for example, may be produced from organic dicarboxylic acids with 2 to 12 carbon atoms, preferably aliphatic dicarboxylic acids with 4 to 6 carbon atoms, and polyhydric alcohols, preferably diols with 2 to 12 carbon atoms, and more preferably 2 to 6 carbon atoms.
  • Suitable dicarboxylic acids include, for example, succinic acid, malonic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, decanedicarboxylic acid, maleic acid, fumaric acid, phthalic acid, isophthalic acid and terephthalic acid.
  • the dicarboxylic acids may, in this connection, be used individually as well as in the form of mixtures.
  • the corresponding dicarboxylic acid derivatives such as e.g.
  • dicarboxylic acid monoesters and/or diesters of alcohols with 1 to 4 carbon atoms or dicarboxylic acid anhydrides may also be employed in the preparation of these polyester polyols.
  • Dicarboxylic acid mixtures of succinic acid, glutaric acid and adipic acid are preferably used in quantitative ratios of, for example, 20 to 35 parts by weight of succinic acid, 35 to 50 parts by weight of glutaric acid, and 20 to 32 parts by weight of adipic acid, with the sum of the parts by weight of succinic acid, glutaric acid and adipic acid totalling 100 parts by weight. It is particularly preferred to use mixtures of dicarboxylic acids which contain adipic acid.
  • dillydric and polyhydric alcohols examples include ethanediol, diethylene glycol, 1,2-propanediol and 1,3-propanediol, dipropylene glycol, methylpropanediol-1,3,1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, 1,10-decanediol, glycerol, trimethylolpropane and pentaerythritol.
  • ethanediol diethylene glycol, 1,2-propanediol and 1,3-propanediol
  • dipropylene glycol methylpropanediol-1,3,1,4-butanediol
  • 1,5-pentanediol 1,6-hexanediol
  • neopentyl glycol 1,10-decanediol
  • mixtures of two or more of ethanediol, diethylene glycol, 1,4-butanediol and 1,6-hexanediol, glycerol and/or trimethylolpropane are particularly preferred.
  • compounds which may also be used include polyester polyols of lactones, e.g. ⁇ -caprolactone or hydroxycarboxylic acids, e.g. o-hydroxycaproic acid and hydroxyacetic acid.
  • polyester polyols there may furthermore be mentioned the polycarbonates containing hydroxyl groups.
  • polyester polyols have a number average molecular weight of 1,000 to 4,000 g/mole, and a functionality of 1.7 to 4, preferably 1.8 to 3.5.
  • Suitable as polymer polyols in b2.1)(ii) are the ester based polymer-modified polyols that have already also been mentioned above as being suitable for component b 1.4).
  • b2) additionally comprises b2.2) from 5 to 48 wt. % of one or more polyether polyol components.
  • polyether polyols are selected from the group consisting of (i) one or more polyether polyols containing ethylene oxide groups and having a number average molecular weight of 900 to 18,000 g/mole, a functionality of 1.7 to 4, and an ethylene oxide content of 10 to 40 wt. %, and (ii) one or more ether-based polymer polyols having an OH number of 10 to 149, a mean functionality of 1.7 to 4, and which contain from 1 to 50 wt. % of solids, based on the total weight of polymer polyol.
  • Component b3) of the invention comprises one or more polyether polyol components having a number average hydroxyl functionality of 2.02 to 2.95.
  • Suitable polyether polyols are those selected from the group consisting of b3.1) at least one polyether diol with an hydroxyl number of 10 to 115 and that is produced by propoxylation of a difunctional starter, with subsequent ethoxylation of the propoxylation product, while maintaining a weight ratio of propylene oxide to ethylene oxide of 60:40 to 85:15, and b3.2) at least one polyether triol which optionally contains solids based on styrene/acrylonitrile copolymers, polyureas or polyhydrazocarbonamides in an amount of up to 20 wt.
  • polyether triol has a hydroxyl number of 12 to 56, and is produced by propoxylation of a trifunctional starter with subsequent ethoxylation, while maintaining a weight ratio of propylene oxide to ethylene oxide of 60:40 to 85:15.
  • suitable polyether polyols used include those which are obtained by alkoxylation of suitable starter molecules, preferably polyhydric alcohols.
  • the starter molecules are at least difunctional, but may, however, optionally also contain proportions of higher functional, in particular trifunctional, starter molecules.
  • the alkoxylation is normally carried out in two steps.
  • alkoxylation is carried out in the presence of basic catalysts or double metal cyanide catalysts, preferably with propylene oxide or, less preferably, with 1,2-butylene oxide or, even less preferably, with 2,3-butylene oxide, and then followed by ethoxylation with ethylene oxide.
  • the proportion of ethylene oxide in the polyether polyol is 10 wt. % to 40 wt. %, preferably 15 wt. % to 35 wt. %, and more preferably 18 wt. % to 32 wt. %.
  • the ether-based polymer polyols used in component b2.2), specifically as component b2.2)(ii) and as component b3.2) a polyether triol which contains solids are preferably polymer-modified polyols, and in particular graft polymer polyols based on polyethers.
  • Suitable grafting components are, in particular, those based on styrene and/or acrylonitrile, which are produced by in situ polymerisation of acrylonitrile, styrene, or preferably mixtures of styrene and acrylonitrile.
  • mixtures of styrene and acrylonitrile include those mixtures containing styrene and acrylonitrile present, for example, in a weight ratio of 90:10 to 10:90, and more preferably in a weight ratio of 70:30 to 30:70.
  • the polymer polyols may be present as polyol dispersions, which contain as dispersed phase, for example, polyureas (PHD), polyhydrazides, and polyurethanes containing bound tert.-amino groups.
  • PLD polyureas
  • polyhydrazides polyhydrazides
  • polyurethanes containing bound tert.-amino groups for example, polyureas (PHD), polyhydrazides, and polyurethanes containing bound tert.-amino groups.
  • Chain extenders and/or crosslinking agents are used as component c) in accordance with the present invention.
  • Such chain extenders/crosslinking agents are used to modify the mechanical properties, and in particular, the hardness of the molded part.
  • polyols with number average functionalities of above 2 and up to 8, preferably 2.1 to 5, particularly preferably 3 to 4 may also be used in conjunction, e.g. 1,1,1-trimethylolpropane, triethanolamine, glycerol, sorbitan and pentaerythritol, as well as polyethylene oxide polyols started on triols or tetraols, which have mean molecular weights of below 750 g/mole, preferably 62 g/mole to 400 g/mole, and more preferably 62 g/mole to 200 g/mole.
  • Each member of the group of diols may be used either individually or in combination with other diols and polyols.
  • Crosslinking agents include, in addition to the aforementioned polyols, compounds such as, e.g. triols, tetraols, oligomeric polyalkylene polyols, and also aromatic and aliphatic amines and diamines with a functionality of 2 to 8, preferably 2 to 4, which normally have molecular weights of less than 750 g/mole, preferably 62 to 400 g/mole and more preferably 62 to 200 g/mole.
  • the component c) is preferably present in an amount of 5 to 25 wt. %, based on the combined weight of the components b) and c).
  • the blowing agent component d) comprises a mixture of component d1), component d2) and component d3).
  • Component d1) is at least one blowing agent selected from the group consisting of nitrogen, air and/or carbon dioxide.
  • the gases used as blowing agent component d1) are added above atmospheric pressure to the components a) and/or b). It is preferred to add these gases to components a) and/or b) at a pressure between 1 and 11 bar absolute.
  • Suitable compounds to be used as blowing agent component d2) include, for example, those physical blowing agents that vaporise under the influence of the exothermic polyaddition reaction, and preferably have a boiling point under normal pressure in the range from ⁇ 30° to 75° C.
  • Other suitable blowing agents for component d2) include chemical blowing agents, such as, for example, water and carbamates.
  • acetone ethyl acetate
  • halogen-substituted alkanes perhalogenated alkanes such as R134a, R141b, R365mfc, R245fa, butane, pentane, cyclopentane, hexane, cyclohexane, heptane or diethyl ether.
  • a blowing effect may also be achieved by adding compounds that decompose at temperatures above room temperature with the release of gases, for example nitrogen and/or carbon dioxide, by using compounds such as azo compounds, e.g.
  • azodicarbonamide or azoisobutyronitrile or salts such as ammonium bicarbonate, ammonium carbamate or ammonium salts of organic carboxylic acids, e.g. monoammonium salts of malonic acid, boric acid, formic acid or acetic acid.
  • blowing agents as well as details of the use of blowing agents, are described in R. Vieweg, A. Höchtlen (Eds.): “Kunstoff-Handbuch”, Vol. VII, Carl-Hanser-Verlag, Kunststoff, 3rd Edition, 1993, pp. 115 to 118, 710 to 715.
  • Suitable to be used as blowing agent component d3) include, for example, the preferred hollow microspheres with enclosed blowing gases or liquids with boiling points between ⁇ 30° and +75° C. and a thermoplastically deformable skin, such as are described in, for example, U.S. Pat. No. 5,260,343, the disclosure of which is hereby incorporated by reference, and are produced and marketed for example by AKZO NOBEL.
  • one or more emulsifier i.e. component e
  • component e may preferably also be added, and in particular, when component d2) of the blowing agent comprises water.
  • Suitable for use as component e are the anionic, cationic, amphoteric or non-ionic (neutral) emulsifiers.
  • auxiliary substances for the production of the molded parts, there may optionally be used further additives and/or auxiliary substances as component f).
  • surface-active additives such as foam stabilizers, cell regulators, flameproofing agents, nucleating agents, antioxidants, stabilizers, lubricants and mold release agents, fillers, dyes, dispersing aids and pigments.
  • Reaction inhibitors, flameproofing agents, antistatics, stabilizers against ageing and weathering influences, plasticizers, viscosity regulators and substances having a fungistatic and bacteriostatic action may also be used.
  • Component g) to be used in accordance with the invention comprises one or more known polyurethane catalysts.
  • Suitable known catalysts include, for example, amine catalysts such as, for example, tertiary amines such as triethylamine, tributylamine, N-methylmorpholine, N-ethylmorpholine, N,N,N′,N′-tetramethyl-ethylenediamine, pentamethyldiethylene-triamine and higher homologues, 1,4-diaza-bicyclo-[2.2.2]-octane, N-methyl-N′-dimethylaminoethyl-piperazine, bis-(dimethylaminoalkyl)-piperazine, N,N-dimethylbenzylamine, N,N-dimethylcyclohexylamine, N,N-diethylbenzylamine, bis-(N,N-diethylaminoethyl)adipate, N,N,N
  • Suitable catalysts also include Mannich bases of secondary amines, such as dimethylamine, and aldehydes, preferably formaldehyde, or ketones such as acetone, methyl ethyl ketone or cyclohexanone, and phenols such as phenol, N-nonylphenol or bisphenol A.
  • Tertiary amines containing hydrogen atoms that are Zerewittinoff-active with respect to isocyanate groups may also be used as the catalyst such as, for example, triethanolamine, triisopropanolamine, N-methyldiethanolamine, N-ethyldiethanolamine, N,N-dimethylethanolamine, and their reaction products with alkylene oxides such as propylene oxide and/or ethylene oxide, as well as secondary and/or tertiary amines.
  • sila-amines with carbon-silicon bonds e.g. 2,2,4-trimethyl-2-silamorpholine and 1,3-diethylaminoethyltetramethyl disiloxane.
  • NCO groups may also be used as additional catalysts.
  • organometallic compounds of tin, titanium, bismuth, and in particular organotin compounds may also be co-used as additional catalysts.
  • Suitable organotin compounds in addition to sulfur-containing compounds such as di-n-octyl tin mercaptide, are also preferably tin(II) salts of carboxylic acids, Such as tin(II) acetate, tin(II) octoate, tin(II) ethylhexoate, tin(II) laurate and tin(II) compounds, e.g. dibutyltin oxide, dibutyltin dichloride, dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate or dioctyltin diacetate.
  • tin(II) salts of carboxylic acids Such as tin(II) acetate, tin(II) octoate, tin(II) ethylhexoate, tin(II) laurate and t
  • the molded parts of the present invention can be accurately produced from the components a) to f) in the mold and without so-called core burning.
  • These molded parts are preferably employed as particularly light shoe soles, which are especially suitable for bath slippers, beach sandals and house shoes. They may also be used as plates and/or component parts of shoes.
  • component A comprised: the polyol mixture; and component B comprised: the isocyanate component.
  • component A comprised: the polyol mixture
  • component B comprised: the isocyanate component
  • component C comprised a batch consisting of a part of component A plus hollow microspheres.
  • polyester base 40° to 45° C.
  • polyether base 30° to 35° C.
  • the mold temperatures were maintained between 53° and 60° C.
  • the CO 2 was added to the polyol component or to the polyol component and the isocyanate component by means of a gassing device from the Desma company.
  • Polyisocyanate 1 Desmodur ® PF from Bayer MaterialScience AG
  • Polyisocyanate 2 Desmodur ® VP PU 0926 from Bayer MaterialScience AG
  • Polyol 1 EG-BD-(polypropylene/ethylene oxide) adipate, OH No. 55 (a polyether ester polyol)
  • Polyol 2 EG-BD-polyadipate; OH No. 55 (a polyester polyol)
  • Polyol 3 PO-EO (80/20) polyol, OH No. 28 (terminal EO), molecular weight of 4,000
  • Polyol 4 PO-EO (85:15) polyol, TMP-started, OH No.
  • Emulsifier 1 diphenyl polyglycol ether, OH number of 80 and molecular weight of 450, an emulsifier from Bayer MaterialScience AG
  • Emulsifier 2 diisobutyl phthalate, a plasticiser from Bayer MaterialScience AG
  • Emulsifier 3 Adimoll DO from Bayer MaterialScience AG
  • Stabilizer 1 OS22 from Bayer MaterialScience AG
  • Stabilizer 2 DC 190 from Air Products Catalyst 1: Dabco ® 1027 from Air Products Catalyst 2: Dabco ® BL-11 from Air Products Catalyst 3: UL 1 from Crompton Dabco ® in EG: 80 wt. % Dabco ® dissolved in 20 wt. % ethylene glycol (catalyst) Tela: triethanolamine (a crosslinking agent)
  • Ethanediol a chain extender

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)
US11/069,241 2004-03-05 2005-03-01 Flexible molded parts of expanded polyurethane and their use Abandoned US20050197413A1 (en)

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CN102649874A (zh) * 2012-05-22 2012-08-29 谢秋鸿 聚氨酯橡胶复合材料及其制备方法
US20130023596A1 (en) * 2006-03-24 2013-01-24 Century-Board Usa, Llc Polyurethane composite materials
EP2842979A4 (en) * 2012-04-26 2016-01-20 Momentive Performance Mat Jp POLYURETHANEUM FUEL COMPOSITION AND METHOD FOR PRODUCING A FLEXIBLE POLYURETHANE FOAM
US9745224B2 (en) 2011-10-07 2017-08-29 Boral Ip Holdings (Australia) Pty Limited Inorganic polymer/organic polymer composites and methods of making same
US9752015B2 (en) 2014-08-05 2017-09-05 Boral Ip Holdings (Australia) Pty Limited Filled polymeric composites including short length fibers
US9988512B2 (en) 2015-01-22 2018-06-05 Boral Ip Holdings (Australia) Pty Limited Highly filled polyurethane composites
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US10005218B2 (en) 2012-04-13 2018-06-26 Basf Se Method for producing expanded granules
US10030126B2 (en) 2015-06-05 2018-07-24 Boral Ip Holdings (Australia) Pty Limited Filled polyurethane composites with lightweight fillers
US10472281B2 (en) 2015-11-12 2019-11-12 Boral Ip Holdings (Australia) Pty Limited Polyurethane composites with fillers
WO2021012139A1 (en) * 2019-07-22 2021-01-28 Dow Global Technologies Llc Polyurethane compositions, products prepared with same and preparation methods thereof
US11142624B2 (en) * 2016-02-09 2021-10-12 Bauer Hockey Llc Athletic gear or other devices comprising post-molded expandable components
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WO2007058947A3 (en) * 2005-11-10 2008-07-24 Ixtlan Technology Llc Multi-density flexible foam
WO2007058947A2 (en) * 2005-11-10 2007-05-24 Ixtlan Technology, Llc Multi-density flexible foam
US20130023596A1 (en) * 2006-03-24 2013-01-24 Century-Board Usa, Llc Polyurethane composite materials
US20140163128A1 (en) * 2006-03-24 2014-06-12 Century-Board Usa, Llc Polyurethane composite materials
US9512288B2 (en) * 2006-03-24 2016-12-06 Boral Ip Holdings Llc Polyurethane composite materials
CN101613455B (zh) * 2009-08-05 2011-04-06 旭川化学（苏州）有限公司 高固含量型聚氨酯树脂组合物及其制备方法
US9745224B2 (en) 2011-10-07 2017-08-29 Boral Ip Holdings (Australia) Pty Limited Inorganic polymer/organic polymer composites and methods of making same
US10005218B2 (en) 2012-04-13 2018-06-26 Basf Se Method for producing expanded granules
EP2842979A4 (en) * 2012-04-26 2016-01-20 Momentive Performance Mat Jp POLYURETHANEUM FUEL COMPOSITION AND METHOD FOR PRODUCING A FLEXIBLE POLYURETHANE FOAM
CN102649874A (zh) * 2012-05-22 2012-08-29 谢秋鸿 聚氨酯橡胶复合材料及其制备方法
US9752015B2 (en) 2014-08-05 2017-09-05 Boral Ip Holdings (Australia) Pty Limited Filled polymeric composites including short length fibers
US9988512B2 (en) 2015-01-22 2018-06-05 Boral Ip Holdings (Australia) Pty Limited Highly filled polyurethane composites
US10030126B2 (en) 2015-06-05 2018-07-24 Boral Ip Holdings (Australia) Pty Limited Filled polyurethane composites with lightweight fillers
US10472281B2 (en) 2015-11-12 2019-11-12 Boral Ip Holdings (Australia) Pty Limited Polyurethane composites with fillers
US11142624B2 (en) * 2016-02-09 2021-10-12 Bauer Hockey Llc Athletic gear or other devices comprising post-molded expandable components
US11142623B2 (en) 2016-02-09 2021-10-12 Bauer Hockey Llc Athletic gear or other devices comprising post-molded expandable components
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CN108192332A (zh) * 2017-12-26 2018-06-22 东莞市雄林新材料科技股份有限公司 一种用于减振器内芯的聚氨酯弹性体材料及其制备方法
WO2021012139A1 (en) * 2019-07-22 2021-01-28 Dow Global Technologies Llc Polyurethane compositions, products prepared with same and preparation methods thereof
CN114127146A (zh) * 2019-07-22 2022-03-01 陶氏环球技术有限责任公司 聚氨酯组合物、用所述聚氨酯组合物制备的产品和所述产品的制备方法
US20220315690A1 (en) * 2019-07-22 2022-10-06 Dow Global Technologies Llc Polyurethane compositions, products prepared with same and preparation methods thereof
WO2022195398A1 (en) * 2021-03-15 2022-09-22 Toscana Gomma S.P.A. Process for making a polyurethane gel

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